Fuel Management System Programming Guide T5 Series Software Revision 1.7.4 Franklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USA Tel: +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433 • www.franklinfueling.
Notice Franklin Fueling Systems (FFS) strives to produce the finest manual possible and to ensure that the information that it contains is complete and accurate FFS periodically review the manuals. However, FFS reserves the rights to change this document and specifications at any time without notice. FFS makes no expressed or implied warranty with regard to the contents of this manual.
Contents Notice.................................................................................................................................. ii Important Safety Messages............................................................................................... 1 Introduction......................................................................................................................... 3 FMS Functions...........................................................................................
Programming Parameters................................................................................................................ 28 Fuel Management System........................................................................................................................28 Special Tanks............................................................................................................................................29 Manifold Tank System.....................................................
Important Safety Messages FFS equipment is designed to be installed in association with volatile hydrocarbon liquids such as gasoline and diesel fuel. Installing or working on this equipment means working in an environment in which these highly flammable liquids may be present. Working in such a hazardous environment presents a risk of severe injury or death if these instructions and standard industry practices are not followed.
Warning Substituting components could impair intrinsic safety. T5XXXs are intrinsically safe for sensors installed in – Class I, Division 1, Group D – hazardous locations. Substitution of components could make the energy limiting circuitry in the system ineffective and could cause an explosion hazard. Repairs to a T5XXX console or attached components should only be performed by a qualified, factory-trained technician.
Introduction The purpose of this manual is to guide installers, operators and technicians through programming and troubleshooting the T5 series console, so that it’s configured based on a site’s specific needs. The Fuel Management Systems (FMS) application within the T5 Series consoles tie together the monitoring and alarm capabilities of preceding automatic tank gauges with advanced technologies to supply tank and level data more accurately and efficiently.
Definitions and Acronyms Module – A module is a plug-in card within the T5 series console that is used to perform various functions of the console. The modules are used for field wiring of the input and / or output of electrical signals between different functional equipment pieces. RS-232 – An IEEE standard for serial communication using a 9-pin connector. RS-485 – An IEEE standard for serial communication using Shielded Twisted Pair or Unshielded Twisted Pair wiring.
General After the Fuel Management System has been installed, typically your interaction with the system will be from the LCD display, on-board printer; or using the Web Browser software to program and monitor the console remotely. Remote operation can be performed from a PC, either attached directly or through a network connection to the console. All of the features of the console are available through these input / output devices.
Password Login 1. Press the User Roll icon 2. Enter Password for the desired level as described in the Access Control section on page 5. Default passwords are as follows: Guest: guest User: user Administrator: admin Tapping twice on the User Role Icon will reset to guest level access. Modifying Passwords For initial settings and continuous security purposes, the console will allow you to change any password used for accessing console functions.
Configuring IP Settings for Communication Before attempting to modify any computer settings, contact the Information Technologies department of your business, if available. Some computer accounts may have restricted permissions to overcome before any changes are allowed to be made to TCP / IP settings. Note: If setting up a connection with a newer operating system (i.e. MS Vista or Widows 7), contact FFS Technical Support for assistance. At the PC: 1.
• In Classic View, click on Network Connections. 4. Right-click on Local Area Connection and select Properties. 5. In the Local Area Connection Properties dialog box, under “This connection uses the following items,” select Internet Protocol (TCP / IP) and click Properties. There are many ways to configure a computer to communicate with a T5 series console. These factors are dependent on the user’s computer knowledge and how the computer is currently configured.
Obtain an IP Address Automatically Computers commonly use this setting to obtain an IP address automatically. 1. If Obtain an IP address automatically is selected, it may be best to click the Alternate Configuration tab. Note: The consoles default IP address is 192.168.168.168.
Connecting a PC to the T5 series RS-232 Port COMM 1 is used to connect a PC or laptop with the console via the Web Browser Interface for programming or remote monitoring. COMM 2 is used only for VRM to retrieve ullage data from an external ATG. If serial connection to Point-Of-Sale (POS) is desired for report retrieval, then we suggest using COMM 1 in Veeder-Root (VR) mode.
5. Enter a Computer Name (it can be the site name). 7. Select My use only. 6. Select the communication port to be used from the Select a Device drop-down list. 8. For convenience, a shortcut may be created on your desktop. Click Finish to complete the wizard. 9. In the Network Connections window, right-click the new direct connection that was created and select Properties.
10. Under the General tab, select Configure. 15. Leave the existing Redialing Options as they are. 11. Change the Maximum speed (bps) to 57600. 12. Disable all of the Hardware Features and click OK. 16. Select the Security tab. 17. Select Advanced (custom settings). 13. Select the Options tab. 14. Disable all of the Dialing Options. 18. Select the Networking tab.
19. In the Type of dial-up server I am calling, select PPP: Windows 95 / 98 / NT4 / 2000, Internet from the drop-down list then click OK. Check Operation of Connection 1. As before, open Network Connections. 2. Right-Click the new direct connection and select Connect. The status should change to connected. At this point, the computer is connected to the console. If you experience technical difficulties, please contact Franklin Fueling Systems Technical Support before proceeding.
Configuration and Preferences Configuration and Preferences include how information will be displayed and configuring the console for its location and communication and access options. Preferences Menu Starting at the Home Menu, press the Main Menu And then select Preferences button. . Use the Preference tables on the following pages to select the menu options to be changed.
Numbers Options Group digits by 10 using specified symbol (i.e. either “123456789” or “123,456,789”). 3 Digit grouping Digit grouping symbol Decimal symbol Symbol used to group digits (i.e. ‘, ’; ‘ _ ‘…). User defined option. Symbol used to separate decimal units (i.e. ‘.’; ‘,’). User defined option. Display leading zeroes Displays decimals with leading zero (i.e. with ‘0.123’; without ‘.123’).
Configuration Menu Configuration Options Using the options in this menu, you can change: • Console passwords • COM 1 parameters • Network parameters • Modem Parameters • Current time and date and set an accurate time zone. For instructions on setting passwords, see pages 5 & 6: Access Control. Once the console has been powered up, navigate the console by pressing the screen on the appropriate button. 1. Starting at the Home Status Menu, press the Main Menu button. 2. Select the Configuration button.
Time Zone Set the Time Zone according to your geographical location. If your choice does not appear on the first screen, use the navigation up and down buttons to scroll through more options. When finished, confirm your selection by pressing the check-mark or OK button. Remote Logging Host Logging event information can be done remotely by using this option. Type the address of the remote host that the console will communicate with.
Programming and Navigation Console Navigation The operating system is designed for easy navigation. Applications allow the user to modify programming options by responding to on-screen commands. The following instructions show various operating system functions, so that issues can be corrected efficiently without interrupting dispensing or sales. Access application sub-menus within the console by pressing the corresponding menu option button on the display. Graphical icons are used to navigate the console.
Character Navigation Buttons When prompted to enter system information, press the corresponding keys. Character Selection: Selects between upper case letters, lower case letters and numerals. Note how the characters on the input buttons change as you scroll through the options. Backspace: This will move the cursor one space to the left and delete the last character. Clear: Deletes all of the data on the entry line. Enter: Allows the data to be accepted.
Programming System Parameters Using the touch screen function of the console to program, navigate from the Home Status screen by pressing the Main Menu button. At the Main Menu, press the Setup button, and select System ID. The System ID screen looks like this: To make a modification, select the parameter that you want to change. Type the new setting in using the characters available. When finished, press the check-mark.
Programming Modules The Fuel Management System is composed of a custom set of modules. Each module maintains individual characteristics. Parameters must be set to match the site configuration. The programming table below will assist in this setup. Remote Data Transfer Units (DTU’s) Remote Data Transfer Units (DTU’s) are used in California for the purpose of relaying information from various sensors mounted in dispensers to the FFS console.
Probe Modules The Probe Module gather data from probes, vapor flow meter and TS-DMS sensors. This information is processed by the Controller Module for use in inventory, reconciliation, V/L Ratio calculation, TS-DMS sensor alarms and to provide information for reports. If a DTU is being used there will be an option for a “virtual module” labeled Remote Module. The Remote Module gathers information from the vapor flow meter when a DTU is used.
4-20 mA and 4-20 mA EXP Input Modules The Analog Input Module has 8 identical channels for loop powered IS sensors with a 4-20 mA interface. The 4-20 mA EXP module is programmed in the same manner. The 420 EXP module is located on the hazardous side of the console, must have the wires enclosed in explosion-proof conduit, and has a red front. If a DTU is being used there will be an option for a “virtual module” labeled Remote Module.
Power Supply Module The Power Supply is a non-intrinsically safe module that provides power to the T5 series console from line voltage rated 110 - 240 VAC. This module is two inches wide, occupies two slots and is located immediately to the right of the Controller Module. The Power Supply Module has two AC / DC switching power supplies: one power supply is +5 V and the other is +24 V.
Group Name RS-232 Relays Channel # Parameter Name Baud Rate Data Bits Parity Low Voltage Inputs Channel # LON (9600) (8) (None) Stop Bits (1) Response Time-out (8) Description Data transmission speed in bits per second. Number of bits that represent data. Value of parity (error check) bit. Number of stop bits, notifies receiving device of end of data packet. Period of time the console will wait for a response from a remote device.
Relay Modules The Relay Module is a non-intrinsically safe module that has 8 identical Form C output channels. Each channel has a fuse and three terminals. Each channel can be configured as NO or NC with the power off by wiring to the appropriate terminals. Group Name Parameter Default Parameter Name Description Parameter Input Relay Modules Module # Channel # 10 Amp Channels (No) (0) Select Yes if this is the 10 Amp relay module. Number of relays used on this module.
Dispenser Interface The Dispenser Interface is used in VRM and Reconciliation applications to communicate sales data from the dispensers to the console. Group Name Parameter Name Parameter Default Description Parameter Input Dispenser Interface Precision Volume Precision Dispenser Volume (3) (Gross) Number of Grades Name Include in Vapor Recovery (0) (1) (Yes) The number of digits to the right of the decimal point. Select Gross if the dispenser volume is not temperature compensated.
Programming FMS Parameters Here is where specific equipment parameters will be modified to match the site setup. Fuel Management System Group Name Fuel Management System Parameter Name Ullage Percent (95) Delivery Delay (15 min) Correction Temperature High Product Limit Static Tank Testing Tanks Region (3.00 gph) Percent of tank level used to calculate space left. Time after delivery when increase is reported. Product temperature correction.
FMS Parameters Continued Group Name Parameter Name Parameter Default Description Parameter Input Fuel Management System Special Tanks Special # Shape (Horizontal cylinder) Physical shape of the tank. • Horizontal Cylinder • Vertical Cylinder • Rectangular Length Diameter (160.00 in) (96.00 in) End Type (Cylinder) Length of tank in inches. Diameter of tank in inches.
Manifold Continued Group Name Special Products Special N Parameter Name Correction Type API Gravity Lines Line# Alpha Density Mole Weight Vapor A Vapor B Number of lines Name Submersible Pump module TPI Submersible Pump Channel Transducer Enable SLLD Product Enable Monthly Compliance Annual Compliance Pressure Up Test Wait Time Catch Pressure Wait Time Dispenser Pressure Test Parameter Default (Table 6A) As defined by the fuel provider (63-500) As defined by the fuel provider (600.000) (500.
Group Name Reconciliation Autocalibration Parameter Name Parameter Default Over Short Limit Percent (1.00%) Over Short Limit Volume (130.
E-Mail Group Name E-Mail Parameter Name “From” Address SMTP Host SMTP Port Enable Authentication Maximum Queue Size Retry Timeout Parameter Default your_from@address. com your_smtp_host_ address 25 No 20 3600 Watchdog Timeout 30 Enable Debugging (No) Description Address of sender (console). IP address of SMTP Host. Port address of SMTP. Data authentication (if required). Maximum size of queue in Megabytes. Time, in seconds, that the console will wait before attempting to resend the message.
Web Browser Interface Navigating Applications Remotely The Web Browser Interface offers several ways to navigate through applications: • Easy-to-read web pages that use hyperlink text (words or characters that, when clicked, take you to another page) to move through the menus, • Text and drop boxes and buttons allow inputs to be made efficiently, • On-screen prompts automatically pop-up instructions to verify each step.
Backup Setup Files Download Backup allows you to download the setup file and store it on any PC connected to the console. This file can be uploaded to the console to recover lost settings or copy settings from one site to another. 1. Open a web browsing application, type the IP address (the default IP address is 192.168.168.168) into the address bar of the browser window. 2. The console will navigate to the Home Status page, indicated by the word Status displayed in the header. 3.
Upload When required, the backup configuration file will need to be reloaded onto the console to restore a previous setup. When uploading, it is important to remember that network parameters may be affected by the change, rendering it unreachable from a remote location. If the downloaded file contains an IP address different from the one currently in use, someone will need to locally reprogram the correct address into the console in order to communicate remotely. 1.
Leak Testing All T5 series console models meet (or exceed) the requirements of the U.S. Environment Protection Agency (EPA / 530 / UST-90 / 006 test protocol) for Automatic Tank Gauging Systems (ATGS) for Monthly Monitoring for 0.2 gal/hr leaks of Underground Storage Tanks. The system(s) also meet (or exceed) the requirements for Annual Tank Tightness Testing for 0.1 gal / hr leaks of the National Work Group on Leak Detection Evaluations (NWGLDE).
Manually Forcing Static Leak Tests 1. To force a Static Tank Leak test, press the FMS button in the Application Window. 4. The FMS Control Menu will display the systems available for testing. To view control options for the tanks system, press the Tanks button. 2. Press the Application Menu button. 5. On the FMS Tank Control Screen, press the button that corresponds with the tank to be tested. 3. Select the Control button in the FMS Menu. 6.
Tank Leak Test Results Leak test results are either increase, passed, failed, or indeterminate. Reasons Why Tank Leak Tests Fail • The tank leaks. • Temperature instability – temperature variations of the product within the tank after a delivery is the most common source of interference and failed leak tests / false alarms (a failure to detect real leaks can also result). Look at the hourly temperature data on the leak test report and retest if the variation is more than a few tenths of a degree.
TS-LS500 Auto Learn Line Leak Testing Overview A 0.2 gph and a 0.1 gph test line leak tests can be started from the console. Some jurisdictions recommend that a 0.1 gph annual precision line leak test be run yearly. The 0.2 gph test runs automatically on a daily basis. The coarse 3 gph line test runs automatically after every dispense. State and local regulations may require more frequent tests and inspections.
DTU (Data Transfer Unit) Setup and Programming 1. Under Setup / System Configuration/Modules Expected, set Console DTU to 1. 2. Under Setup, locate Remote DTUs. The Network ID number will be defaulted to 1. 3. Enter the number of Remote DTUs installed in Number of Units. Note: Remote DTUs refers to the units in dispensers only. 4. For each Remote Data Transfer Unit, you must enter the unique Unit ID #. This number can be found on the label included with each Remote DTU. Enter this number for each one. 5.
9. Under Setup/4-20mA Input Modules (DTU) / locate Remote Module 2 and enter the number of DTUs installed. The maximum number of channels per a 4-20mA Input Module is 8. 10. If more than 8 DTUs are used, program the next Remote Module. Follow steps 8 and 9 to complete the Remote Data Transfer Units 11. For the 4-20mA Input Module programming, one channel will correspond to the dispenser that houses the ISD Pressure Sensor. This channel is setup as follows; 12. Enter a Name for the ISD Pressure Sensor 13.
DIM Programming 1. For Web Browser programming capability, connect a computer to the T5 series tank gauge. (See programming section of this manual for connection information) 2. From the Home screen, click Setup 3. Click System Configuration, then Modules Expected. Note: The TS550 and TS5000 tank gauge systems can be built with the DIM module installed in the console. It is also possible to have DIM capability installed by a technician in the field.
11. Communication refers to the method of communication used by the corresponding distribution box. Some typical examples: • Current loop-Gilbarco PA0261x000011-PA0261x00020, Wayne/Dresser D-Box • RS422/485-Gilbarco PA0261x000011-PA0261x000021 • RS232 Duplex-Gilbarco MOC G-Site Systems 12. Under Dispenser Interface, select Grades. 13. Number of Grades refers to the number of grades used at the site. Select the appropriate number from the drop down list. 14.
15. Under Dispenser Interface, select Fueling Points. Note: A Fueling Point is anywhere a vehicle can stop and dispense fuel. Most dispensers have two fueling points. (front and back). 16. Select the Number of Fueling points from the drop down list. 17. Under Fueling Points, select Fueling Point 1. 18. Select the Number of Hoses from the drop down list.
There are two ways to program the Hose Position: • Manually-If you know the D-Box grade position you can manually select the Position number from the drop down list. Query Button • By selecting Q next to the Fueling Point, the gauge will automatically Query the D-Box and fill in the information. For the Query function to work, all equipment must be installed and connected, and all positions must be set to 0.
Dual DIM Installation Some sites and dispenser configurations may require the use of a second DIM module that would be installed externally to perform reconciliation or VRM. This section outlines the special installation steps required to install a second TS-DIM on a T5 series console. Hardware Configuration In order for the external TS-DIM module to communicate properly with the T5 series console a few jumpers will need to be adjusted.
TS-TPI Overview and Functionality Tank fuel management can be achieved using a Franklin Fueling Systems T5 Series Fuel Management Systems and an FE Petro Turbine Pump Controllers (STP-SC1, EcoVFC or MagVFC). Refer to Bulletin TB1010-04 for connecting to an STP-SCIII controller. Tank Fuel Management looks at percent (%) full volume of individual tanks and gives priority to the submersible pump needed to control tank inventories.
TPI Setup Group Name Parameter Name Parameter Default Description Max Value Power Supply RS-485 TS-TPI Enable Interface Controllers A* Number of Controllers Controller 1 Name Enabled Type (Yes) (2) Unlead Pump 1 (Yes) (1) Group (0) Tank (1) Number of Inputs Input 1 Type Channel Controller 2 Name Enabled Type Number of controllers to be connected Given Name of the pump controller Enables the controller. Type of controller used (Mag/ECO) Address Height Enables TS-TPI options. (5.
List of Alarms and Troubleshooting For all alarms conditions, the troubleshooting steps provided in this chapter are suggested actions to take in the event of an alarm. Follow all site policy procedures set by local governing agencies in the case of a spill, leak, or malfunction. If the steps provided by this manual or the site policy are followed and the system still requires additional support, contact Franklin Fueling Systems Technical Services.
Displayed Alarm / Warning Description Console DTU is offline Slot Console DTU number mismatch Slot Controller Module is Offline Slot Controller Module is offline due to unknown causes. DIM module number mismatch Slot DIM modules detected does not match the number programmed. System There is an internal buffer error occurring in the gauge. The configuration that has been loaded is not valid. The registration that is loaded is not valid.
Displayed Alarm / Warning Device Description Recommended Actions slot Relay Modules detected does not match the number programmed. Relay Module Setup Error None Secondary Containment Monitor Setup Error None An error exists in the Relay Module configuration An error exists in the configuration of the Secondary Containment Monitoring Setup. Data transfer errors occurred in the System Bus. There is an error in the Setup configuration.
Displayed Alarm / Warning VFM No Data VRM Weekly Vapor Collection Failure VRM Weekly Vapor Collection Warning VRM Weekly Ullage Pressure Warning Weekly Ullage Pressure Failure VRM Weekly Ullage Pressure Leak Test Failure VRM Weekly Ullage Pressure Leak Test Warning VRM Remote DTU is Offline DTU DTU FFS Interference DTU DTU Non FFS Interference DTU FMS Alarms 52 Device VRM Description Recommended Actions The Vapor Flow Meter is detected but is not communicating with the Console A Wee
Displayed Alarm / Warning Device Description Recommended Actions High product volume Tank The specified tank has reached the programmed High Product Volume. High High product volume Tank The specified tank has reached the programmed High High Product Volume. High water level Tank Level error Tank Line monitor disabled Line Low battery Tank Water level exceeded High limit set. Product level exceeds tank diameter due to an error in console of programming.
Displayed Alarm / Warning Description Manifold low low product volume Tank The specified manifold has reached the programmed Low Low Product Volume Manifold Leak Detected Tank Manifold Theft Detected Tank Modem Error None A leak in the specified manifolded tanks has been detected via a SCALD test. Suspect possible leak. The specified manifold has entered Sentinel Mode and detects product leaving the tank that exceeds the programmed theft limits. Indicates that a modem malfunction has occurred.
Displayed Alarm / Warning Device SCM Alarms Containment Not Learned SCM Containment Program Error Detected Containment Program Error Warning Containment Pump Request Ignored SCM SCM Engineering Failed to Hold Vacuum SCM Failed to Reach Target Vacuum SCM Low Vacuum SCM Low Vacuum And Pump Request Ignored Not Configured Engineering SCM Unstable Vacuum SCM Vacuum Sensor Failed SCM Vacuum Too High SCM Wire Sensor Alarms Displayed Alarm / Warning Device Description Recommended Actions Th
Displayed Alarm / Warning Device Description SN3 Pwr Short Slot SN3 Sensor On ChannelSN3 Discriminating sensor shows alarm status. SN3 Sump Full ChannelSN3 3-wire sensor detected sump full of liquid. SN3 Sync Error ChannelSN3 3-wire sensor data signals not in sync with module. SN3 Vapor ChannelSN3 3-wire discriminate sensor detecting vapors at location. Visually inspect area for product presence. Verify the vapor level has been calibrated correctly.
Displayed Alarm / Warning Device Description Line Not Learned Line Specified line not learned. Line Program Error Detected Line Pump Request Ignored Line An error has been detected in the programming of the specified line. The line has called for the pump to be turned on but another application is currently using the STP The last passed gross test detected a leak just under the 3 gph threshold. The Console has detected a line leak greater than 0.2 gph.
Displayed Alarm / Warning Device Description Recommended Actions Pump Communication Fail TPI Pump In Water TPI Check all wiring connections and ensure that there is power supplied to the Smart Controller. Ensure proper programming of the TPI and calibration of the Smart Controller. If correct, have water removed from the tank Relay Fault TPI Short Circuit TPI Unbalanced Load TPI Communication from the TPI to the STP controller has failed.
Appendix A - Standard Tanks Table Legend O/C = Owens Corning / FC Fluid Containment D = Diameter (Dia.
Type # 60 Manufacturer Model Capacity (Gallons) Dimensions D x L (inches) S / DW Wall 27 Xerxes — 3,000 96 x 147 S 28 Xerxes — 4,000 75 x 263 S 29 Xerxes — 4,000 96 x 180 S 30 Xerxes — 4,000 76 x 252 DW 31 Xerxes — 6,000 75 x 353 S 32 Xerxes — 6,000 6,000 96 x 246 97 x 251 S DW 33 Xerxes — — 8,000 8,000 96 x 312 97 x 317 S DW 34 Xerxes — — 10,000 10,000 96 x 378 97 x 383 S DW 35 Xerxes — — 10,000 10,000 124 x 257 125 x 262 S DW 36 Xerxes — — 12
Appendix B - Standard Products Table Product Name API Gravity (6B Compensation) Leaded Regular 63.5 Unleaded Regular 63.5 Unleaded Plus 62.8 Unleaded Extra 62.8 Unleaded Super 51.3 Diesel 32.8 Kerosene 41.8 #2 Fuel Oil 32.8 Appendix C - Typical Tank Leak Test Times For 7 Tank Sizes at Half Capacity ( Worst Case is 50% Full ) Tank Size in Gallons Typical - Tank Leak Test Times (to Finish) 4,000 2.0 hours 6,000 3.0 hours 8,000 4.0 hours 10,000 5.0 hours 12,000 6.
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